Process of making whey products



Patented an. 10, 1930 UNITED STATES PATENT; OFFICE NICHOLAS L. SIMMONS,OF WAUSAU, WISCONSIN PROCESS OF MAKING WHEY PRODUCTS No Drawing.Original application filed January 2, 1930, Serial No. 418,175. Dividedand this application filed April 2, 1930.

The present invention relates to a process i of making whey products,and is particular ly concerned with the utilization of the whey which isa by-product in the manufacture of cheese and the like, resulting in theprovision of an improved food product.

. The disposal of the whey which is a byproduct in manufacturingoperations, such as the making of cheese and casein, has long been aserious problem for manufacturing establishments on account of thestench which is caused by the whey within a very short time after itsproduction, and the undesirable pollution of the rivers and otherstreams where this by-product is discharged cheese and caseinmanufacturing establishments, to discharge the whey into sewers, streamsor other bodies of water, because the whey has been an undesirable wasteproduct.

One of the reasons for the universal wasting of the whey by-product, isthe high cost fact that the solids secured by the prior methods havebeen highly hygroscopic, so that they absorb moisture, forming a crustwhich is highly undesirable, and the solid products which have beenproduced by the methods of the prior art have not only been incapable ofutilization in many cases, but have been so expensive that it wascommercially more desirable to waste the Whey than to utilize it.

One of the objects of the present invention is the provision of animproved food product having a high food content of lactose and otherdesirable food ingredients, which is also non-hygroscopic in itscharacteristics so that it may be kept in usable state for a long periodof time without deterioration.

Another object is the provision of an unadulterated or substantiallypure whey product of which substantially all of the lactose is incrystalline or hydrated form, thereby Serial No. 441,180.

rendering the product substantially non-hygroscopic, so that it iscapable of exposure to air and of being stored or shipped according tothe ordinary methods of storing or shipping Without deterioration andwithout caking, lumping, gumming or sticking like the whey products ofthe prior art. The terms unadulterated or substantially pure wheyproducts are used throughout the present specification and claims todistinguish the present product from those other products to which ithas been necessary to add undesirable extraneous ingredients in theprocess of manufacture.

Another object of the invention is the utilization of the whey resultingfrom the manufacture of cheese and from similar operations, in order toeliminate the problem of disposal of this waste by-product, and to makethe whey an additional source of benefit rather than a waste.

proved method of manufacture of food 'material from the whey, whichmaybe practiced by the use of inexpensive equipment on a small scale or alarge scale, thereby utilizing the waste by-product economically withoutthe expenditure of a large investment in machinery or plants. 7

Another object is the production of a whole-whey product which issufiiciently non-hygroscopic to be capable of exposure to variedatmospheric conditions without deterioration, caking, lumping, etc. Theterm whole-whey product 'is 'used throughout the present specificationand claims to distinguish the present products from other whey products,from which certain of the solids have been removed during the process ofmanufacture, so'that said other whey products do not include all of thenatural constituents of whey.

Another object is the production of a Whole-whey product havingsubstantially all of the non-volatile food materials present in thewhey, including crystalline or hydrated lactose, whereby said product issufficiently non -hydroscopic to be exposed to air without developingundesirable characteristics.

Another object is the provision of a simpli- Another objectis theprovision ofan im;

fied and economical process of manufacture of whey powder or solids,which may in many cases be practiced by the manufacturers of productswhich produce whey as a waste by'pr'oduct, with equipment which theyusually have at their disposal, with the slight additional expense ofrelatively inexpensive and simple equipment, thereby turning a wasteproduct into a source of revenue wlthout involving investment of a greatdeal of capital.

Another object is the provision of an improved foodp roduct of such ahigh quality that it is capable of utilization as an ingredient forhuman foods. as well as a relatively cheap food or medicinal agent forstock and poultry.

Another object is the provision of a process of manufacture of wheypowder, which will produce a non-hygroscopic powder, capable of beingpreserved without possibility of lumping, crusting, or otherdeterioration.

Another object is the provision of an improved method of manufacturewhich produces a superior food product from the whey by-productresulting from cheese and casein manufacture.

' Other objects and advantages of the invention will be apparent,as thefollowing description progresses, and it should be understood that thepresent invention includes not only the completeprocess, but the moresimple processes and any of the sub-combinations of steps employed in myprocess.

The invention is of particular importance in the utilization of Wheyfrom the.manufacture of cheese or casein, since the largest volume ofwhey is derived from such manufacture at the present time.

The present application relates particularly to one of the processes ofmaking the whey product and is a division of my prior application SerialNo. 418,157, filed January 2, 1930, for whey products and process ofmaking the same.

The apparatus which is necessary to carry out the following process willbe evident to one skilled in the art from a study of the processdisclosed herein, and consequently itis not necessary to include adetailed description of the apparatus required.

The process for the utilization of the whey is described as follows:

Since the formation of lactic acid begins in the whey soon after itsproduction in the manufacture of cheese. it is preferable that the wheybe drawn directly from the cheese, through a cream sepaator to removethe fat, into the receptacles which are to be utilized in carrying outthe present process.

In the case of the use of a skimmed milk whey, no further centrifugingis required, and in the case of a whole milk whey the step of fatseparation is optional. Since a whole milk whey includes a higherpercentage of butter fat, it will be evident that the finished productmade without the separation of such butter fat will have a higher fatcontent, thereby materially increasing its nutritive properties, but theterm whole-whey is generically applied to any of the types mentionedherein.

The first step in the process, where it is practical to transfer thewhey directly to the vacuum pan, is the concentration of the whey by theremoval of a large percentage of the moisture therefrom, and this stepis preterably accomplished by means of a standard vacuum pan in whichthe whey is subjected to a vacuum and subjected to the influence of heatto evaporate the moisture.

here it is not practical to draw off the whey from the cheese directlyinto the vacuum pan, the whey may be drawn oil' into a reservoir whichinsures a steady supply of whey for the operation of the vacuum pan, andii the whey is to be held for any time at all in the supply reservoir,such as for instance, one or two hours, it should preferably bemaintained at a temperature of about Fahrenheit and agitated by pumpingor any other convenient method of agitation to retard the formation oflactic acid.

It should be noted that the purpose of the step of storage and agitationat the pre ferred temperature, is to insure the continuity of theprocess of manufacture, and while this step is of substantial commercialadvantage, it may be eliminated by the arrangement of the apparatus sothat Whey may be drawn directly from the cheese to the vacuum pan, andin general, it is desirable that the whey be supplied to the vacuum panas quickly and directly as possible.

.-..The step of the concentration of the whey in the vacuum pan may bedone in a single stage or single effect, in which case I prefer tomaintain the vacuum at substantially 22 inches of mercury and thetemperature at substantially 145 Fahrenheit, but it should be understoodthat higher temperatures may be utilized and temperatures as high ashave been employed with good results. In general, the lower temperatureresults in a whiter product, but temperatures lower than 145 cause acorresponding increase in the time required for the concentration of thewhey and at temperatures much above 145 there is a tendency toward theburning of some of the ingredients which tends to discolor the resultingproduct so that the final product may be a light tan or a light brown incolor, rather than the pu e white powder which represents the best formof whey powder having the widest range of use for human food products,as well as stock feed.

The step of concentration is preferably accomplished in a two st agevacuum pan apparatus, also termed a double effect vacuum pan in whichthe vapors resulting from the ill first stage or effect are utilized forheating the product treated in a second stage or effect. In such case,the first effect is preferably run at a vacuum of 12 inches of mercuryor thereabouts, and 162 to 165 Fahrenheit, while the second stage oreffect may be run at a vacuum of 22 inches of mercury andsubstantially-145 Fahrenheit. he doubt effect vacuum pan apparatus hasthe advantage of a more economical utilization of the fuel employed,since the heated vapors from the first stage are utilized for heatingthe second stage. In general, the apparatus should preferably beoperated at the lowest possible-economical temperature, and thetemperatures and pressure indicated should be regarded as exemplary ofsome of the temperatures which are capable of producing highly desirableresults, but not exclusive of other temperatures which may be utilizedby one skilled in the art.

The process of concentration of the whey in the vacuum pan is preferablycontinued until the action in the pan is very slow, and the completionof this step can be determined by one skilled in the art by watching thepan 1' by testing the concentrated whey with a Baum hydrometer. Theconcentration is preferably continued until the resulting prod not isapproximately seventy per cent solid and thirty per cent moisture,although the process may also be carried out at sixty-tire per centsolid or as low as sixty per cent solid, but at such lower percentagesof solids, I find that theconcentrate does not solidify so well. Agreater degree of concentration mightbe accomplished, but at percentagesslightly greater than seventy per cent, it is found that in the nextstep of the process in the'manufacture of the whey product, the materialbe" comes too hard and tends to set ii'rthe pan, but at approximatelyseventy per centsohd, the concentrate is capable of setting to for-m asolid which is slightly mushy,

voirs.

The nextstep in the process is the drawing off of the concentrated wheyinto a setting reservoir, where the whey is permitted to solidify orset, and this step at ordinary temperatures, requires a substantialperiod of time, such as a day. In the preferred practice of the process,the setting may be hastened by placing the concentrate in a reservoirwhich is subjected to refrigeration since it is found that cooling ofthe concentratedecreases the time required f or setting; The explanationofthis 'settingaction is that during the setting. certain ingredients ofthe concentrate. principally the lactose, uiidergo a process 7 ofcrystallization, during which water of crystallization is taken intochemical composition with .said ingredients- In other words, the lactoseconstituents crystallize, or become hydrated,

I but still capable of convenient removal from the setting reser andthe. mineral structure which.

and the present product is therefore capable of being stored in ordinarysacks or open containers without caking, lumping, gumming, sticking 'orotherwise deteriorating. The whey products of the prior art could onlybe preserved by enclosure in hermetically sealed vessels. I

The next step in the process of manufacture is the removal of the excessfree moisture in the whey paste or its desiccation to such a point thatthe resulting product is a substantially dry solid. In order to increasethe exposed air surface of the solids and to expedite the dryingprocess, the Whey prefcrably is spread or separated into smallerparticles, pieces or sheets and placed in some receptacle or upon somesupport. which subjects the greatest amount of solids to the influenceof the moisture absorbing atmosphere. method of accomplishing thisresult is to force the mushy solids through a screen, the particlesfalling upon another supporting screen. The latter support with thesolid material is 'subjcdted toa current of dry and heated air to-remove the excess moisture from the solids. In one form of theapparatus the solids .rest upon a sci een carried by frames, and theframesareplaed in ordinary ovens or drying tunnel s,-while in anotherform of apparatus designed'for continuous operation the solids.,

which passes may be placed upon ascreen belt through an oven, tunnel ortube, and is subjected to a current of hot or dry air. In the lattercase,,the setwhcy product may be extruded through a slot to form a sheetas mentioned above, the sheet being deposited upon the moving belt. Inthe preferred form of apparatus adapted to expeditethe manufacture asmuch as possible, the air may be predricd by cooling-the air to condenseexcess moisture after which the air is heated to increase its capacityfor absorbing moisture and for drying the whey solids.

The drying operation should be accomplished at a ten'u' craturc belowthe temperaheit. In general the lowest temperature which is capable ofeconomical operation should be used. hlYbile the preferred temperatureis about 140 degrees Fahrenheit. l'iie'her temperatures may be used upto the temperature at which the water of crystallization is driven oil,but beyond the preferred temperature the material caramelizes or Oneforms a molasses or sticky mass which is incapable of being ground orhandled satisfactorily in making the present product. Highertemperatures also result in discoloration of the finished product, sothat while the preferred temperature represents the most desirabletemperature, it is not to be regarded as critical but merely asexemplary of one x, a of the desired temperatures at which the dryingoperation should be accomplished.

The drying operation should be continued until the product no longer issoft, but is dry and brittle and suitable for breaking up or grinding.In general, the length of time required for the drying operation isindicated by the appearance and feel of the product and its action inthe grinding machine. The screens which are used may be of any sizecapable of suporting the particles of solid whey, but to inch mesh havebeen found satisfactory at the preferred temperatures indicated above.

The product resulting from such a drying operation is a crystalline orflaky structure consisting of relatively small pieces of whey solidswhich may in some cases be utilized in such form for manufacture ofother food products or for feed. In order to place the material inbetter form for mixing with other food products and for use as a stockfeed, the hand screen frames preferably are shaken over a hopper, or thebelt screen is so arranged as to discharge the dried solids into ahopper of a grinding mill which reduces the solids to a powder or tosuch a predetermined size or particle as is desirable for the use towhich it is intended to be put.

The food product resulting from the foregoing process comprises acrystalline whey powder which is non-hygroscopic in character so thatthe powder does not tend to absorb moisture from the air as has been thecase with the products of the prior art. Consequently, the powder may bestored in bags, or any convenient type of receptacle, and it may be keptfor long periods of time without deterioration.

The present method produces a food prodnot which will dissolve asreadily as ordinary hygroscopic powder, and it may be mixed readily withall kinds of food ingredients as a filler or a flavor. hen used as afeed for poultry, it is found that the whey product is capable ofpreventing coccidiosis or dysentery, and it is highly desirable as afood for stock or chickens on account of the desirable regulatoryeli'ect on the digestive organs. The whey food product is an effectiveappetizer, and has the beneficial properties of the mineral salts ofmilk and also the high food value on account of the presence of lactoseand other food ingredients which were otherwise wasted by the dumping ofthe whey.

One exemplary analysis of one of the products of the process which willindicate the food ingredients present is as follows:

Other uses for the whey powder are the use of the powder as a filler inthe manufacture of cheese and other food products, since the whey powderhas a high food value, and it also may be'utilized for seasoning foodproducts or imparting a distinctive flavor thereto. The powder resultingfrom the preferred practice of the method is a practically pure whitepowder which does not include the undesirable burnt products ordiscolorations of the products of the prior art.

Another advantage lies in the fact that the article can be moreconveniently transported, handled and fed, and present practice ofhauling back rancid whey in the farmers can is eliminated so that thecleaning of the cans may be accomplished at the factory wheresterilizing apparatus is available, thereby insuring a better grade ofcream for butter.

The apparatus required for carrying out the process is extremely simpleand very economical on account of the fact that any system employingvacuum pans is inherently more economical than the spray systems, andsince the system includes a vacuum pan, it generally can be carried outwith existing apparatus withthe mere addition of the apparatus foraccomplishing the drying and grinding operations. The space required forsuch apparatus is very small, thereby effecting great economy over theusual apparatus required for spray methods, and the present process hasthe advantage of flexibility, since it can be installed easily in asmall plant with a small vacuum pan, but it is also capable of largevolume operation with a minimum expenditure of money for machine andplant.

While I have illustrated and described the preferred method of carryingout the process and the most desirable product resulting from such apreferred method, it should be understood that I do not wish to belimited to all of the details of the exact methods described, but desireto avail myself of all changes within the scope of the appended claims.

Having thus described my invention, what I claim is new and desire tosecure by Letters Patent of the United States is:

1. The process of manufacture of a whey product comprising the removalby evaporation of a large percentage of the water content of the whey ata low temperature to avoid discoloration of the product, causing productcomprising the removal by evaporation of a large percentageof the watercon tent of the whey, causing the concentrated whey to set whereby thelactose crystallizes,

. and drying the resulting product in 8. moisture absorbing atmosphereat a temperature below the temperature which effects removal of thewater of crystallization from lactose.

3. The process of manufacture of a whey product comprising the removalby evaporation of a large percentage of the water content of the whey,permitting the concentrated whey to set whereby the lactosecrystallizes, drying the resulting product in a moisture absorbingatmosphere at a temperature below the temperature which effects removalof the water of crystallization, and pulverizing the resulting wheyproduct to a predetermined degree of commlnution.

4. The process of manufacture of a whey product comprising the removalby evaporation of a large percentage of the water content of the whey,causing the concentratedwhey to, set whereby the lactose crystallizes,

spreading the set whey product to increase the drying surface andsubjecting the spread whey product to a moisture absorbing atmosphere ofa temperature below that which effects removal of the water ofcrystallization.

5. The method of utilization of the whey by-product of cheese or thelike comprising transferring whey directly to a concentrating device,concentrating the whey to substantially seventy per cent solids andthirty per cent moisture at a temperature of about 145 Fahrenheit,subjecting the concentrated whey to cooling to effect crystallization,spreading the crystallized whey to expedite drying, drying the resultingproduct at a temperature below the temperature of removal of water ofcrystallization and grinding the resulting solid to a powder.

6. The process of making a whey product which consists in removing asufliciently large percentage of the water content of the whey to inducecrystallization on setting, and 4 permitting the resulting product toset for a sufiicient length of time to effect crystallization of lactoseand to form a substantially homogeneous pasty. mass.

7. The process of making a whey product which comprises removing asufficiently large percentage of the water content of the whey to inducecrystallization on setting, permit- V ting the resulting product to setfor a sufficient length of time to effect crystallization of lactose andto form a substantially homogeneous pasty mass, and further reducing the7 free water content of said mass by -dehydra tion to form asubstantially dry-crystalline whey product.

8. The process of makingawhey product comprising permittinga'concentrated aque ous whey preparation to setto a'pasty mass,

whereinthe lactose is present in crystalline form and dehydratingtheresulting roduot at a temperature belowthat' which e ects removal ofwater of crystallization fromthe lactose. f

9. The process of making a whey product comprising permitting aconcentrated aqueous whey preparation to set to a'pasty mass, whereinthe lactose isj'present in crystalline form, dehydrating the resultingproduct at a temperature below that which effects removal of water ofcrystallization'from the lactoseg and pulverizing the substantially dryprod not to a tion.

10. The

predetermined degree of comminuprocess of making a whole-whey productconslsting in concentrating the whey' to substantially seventy percentsolids and thirty percent moisture in a vacuum pan, re-

moving the resulting concentrate to a setting I reservoir and permittingsaid concentrate to set until the lactose crystallizes.

11. The process of making a whole-whey product consisting inconcentrating the whey to substantially seventy percent solids andthirty percent moisture in. a vacuum pan, removing the resultingconcentrate to a setting reservoir and'subjecting said concentrate torefrigeration to expedite crystallization of the lactose to a pastyhomogeneous mass.

12. The process of making a whole-whey product consisting inconcentrating the whey to substantially seventy percent solids andthirty percent moisture in a vacuum pan at a low temperature to avoiddiscoloration of the product, removing the resulting concentrate to asetting reservoir and permitting said concentrate to set until thelactose crystallizes.

13. The process of making a whole-whey product consisting inconcentrating the whey to substantially seventy percent solids andthirty percent moisture in a vacuum pan at a temperature ofsubstantially 145 Fahrenheit, removing the resulting concentrate to asetting reservoir, and permitting said concentrate to set until thelactose crystallizes.

14. The process of making a whole-whey product comprising concentratingthe whey to substantially seventy percent solids and thirty percentmoisture in a vacuum pan at a low temperature to avoid discoloration ofthe product, removing the resulting concentrate to a setting reservoir,permitting said concentrate to set until the lactose crystallizes into apasty mass, and desiccating said pasty mass at a temperature below thetemperature at which the crystalline lactose caramelizes. 15. Theprocess of making a whole-whey product comprising concentratingv thewhey .to substantially seventy percent solids and thirty percentmoisture in a vacuum pan at a low temperature to avoid discoloration ofthe product, removing the resulting concentrate to a; setting reservoir,permitting said concentrate to set until the lactose crystallizes into apasty mass, extruding said pasty mass upon a support and drying saidmass at a 10 temperature below the tem erature at which discoloration ofthe resulting product takes ace. m p 16. The process of making awhole-whey product comprising concentrating the whey to substantiallyseventy percent solids and thirty. percent moisture in a'vacuum pan at alow temperature to avoid discoloration of the product, removing theresulting concentrate to a setting reservoir, ermitting said concentrateto set until the actose crystallizes into a pasty mass, extruding saidpasty mass upon a moving support, drying said mass to a brittle state,and pulverizing the brittle whey solids to form a powder. In witnesswhereof, I hereunto subscribe my name this 31st da of March, 1930.

NICHO AS L. SIMMONS.

